Image forming apparatus and liquid control method

ABSTRACT

The image forming apparatus comprises: a recording head which discharges droplets of liquid onto a recording medium; a dissolved gas amount estimating device which estimates an amount of dissolved gas contained in the liquid inside the recording head; and a liquid restoring device which carries out restoration processing of the liquid inside the recording head, if an estimated value of the amount of the dissolved gas estimated by the dissolved gas amount estimating device exceeds a prescribed reference value.

This Application is a Divisional of application Ser. No. 11/061,542filed on Feb. 18, 2005 now U.S. Pat. No. 7,416,294, and for whichpriority is claimed under 35 U.S.C. §120; and this Application claimspriority of Application No. 2004-42719 filed in Japan on Feb. 19, 2004under 35 U.S.C. §119; the entire contents of all are hereby incorporatedby reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to an image forming apparatus and a liquidcontrol method, and more particularly, to a liquid droplet controltechnology for controlling the amount of dissolved gas in liquiddroplets used to form an image on a recording medium, and maintainingthe liquid droplets in a desirable state.

2. Description of the Related Art

In recent years, inkjet printers have come to be used widely as dataoutput apparatuses for outputting images, documents, or the like. Aninkjet printer forms data on recording paper by driving recordingelements (nozzles) of a recording head in accordance with data, therebycausing ink to be discharged from the nozzles. Discharge devices forcausing discharge of the ink include devices using PZT actuators, or thelike, which apply a pressure wave to a pressure chamber connected to anozzle, and devices using a heat source which heats ink contained in anink chamber (pressure chamber) and thus generates bubbles in the ink.Ink pressurized by operating a discharge device of this kind isdischarged from the nozzles and data, such as an image, is formed on arecording medium.

In an inkjet printer, if air bubbles become mixed into the ink insidethe recording head, then there is significant loss of the pressureapplied to the ink by the actuator, and this can lead to dischargeabnormalities, such as abnormalities in the amount of ink discharged orthe direction of discharge, discharge failures, and the like. Dischargeabnormalities of this kind affect image recording and consequently causea marked decline in the resulting image quality. Therefore, it ispossible to maintain the quality of the recorded image by detectingdischarge abnormalities swiftly and eliminating the causes of thedischarge abnormalities.

A known method for preventing the occurrence of air bubbles inside aprint head (pressure chamber), which are a cause of dischargeabnormalities as described above, uses a so-called deaerated ink whichhas a reduced amount of gas dissolved in the ink.

Japanese Patent Application Publication No. 2000-190529 discloses amethod for controlling the amount of dissolved gas in a liquid in aninkjet apparatus, an inkjet recording apparatus and a color filtermanufacturing apparatus, according to which the amount of dissolved gasin unused ink that has been circulated within an inkjet head ismeasured, and the ink is circulated and dissolved gas is removed fromthe ink if the measurement value exceeds a prescribed value, in such amanner that the amount of dissolved gas in the ink is equal to or lessthan the prescribed value.

Furthermore, in the inkjet printer and the deaeration method for aninkjet printer described in Japanese Patent Application Publication No.11-20194, a tube provided in the flow path of the ink is reduced inpressure, thereby removing air contained in the ink inside the tube.

In the inkjet recording apparatus described in Japanese PatentApplication Publication No. 11-48491, a deaerating device comprising ahollow fiber filter is provided between an ink container and a recordinghead, in such a manner that ink passes through the deaerating devicewhen supplied to the recording head.

However, if a deaerator and a dissolved oxygen meter for measuring theamount of dissolved gas in the ink are disposed in this sequence beforea print head, from the upstream side of the ink flow path, then sincethere is no device for measuring the dissolved gas downstream of thedissolved oxygen meter, a problem arises in that the amount of dissolvedgas in the ink inside the print head will remain as it is. The same alsoapplies to systems which do not use a device, such as a dissolved oxygenmeter, for measuring the dissolved gas in the ink.

In the method for controlling the amount of dissolved gas in a liquidinside an inkjet apparatus, the inkjet recording apparatus, and thecolor filter manufacturing apparatus according to Japanese PatentApplication Publication No. 2000-190529, since there is a long distancebetween the dissolved oxygen meter that measures the amount of dissolvedgas in the ink and the deaerator, then in cases where the apparatus isprinting at low duty which does not consume ink, or where ink is heldfor a long time inside the inkjet head, or the like, it may occur thatthe amount of dissolved gas in the ink exceeds a specified value when itreaches the dissolved oxygen meter, even though the amount of dissolvedgas does not exceed the specified value in the inkjet head section, andhence the apparatus halts printing and enters deaerating mode, thuscausing time loss.

Furthermore, it is supposed that the deaerator used here hassufficiently high capacity with respect to the flow rate of the ink, butif the ink remains stationary for a long period of time, then thedeaeration rate will exceed the specified value. Moreover, this patentpublication does not provide any description relating to a multiple headin which a plurality of print heads are disposed. For example, if adeaerator is provided at one point of an ink supply path (in otherwords, before branching of the path), then it may not be possible tojudge conditions accurately, due to differences in the use duty of therespective print heads. On the other hand, if deaerators are positionedafter branching in a multiple head, and a dissolved oxygen meter ispositioned downstream of the print heads on the circulation side, thenthe number of deaerators will increase and costs will rise.

Furthermore, in the inkjet printer and deaeration method for an inkjetprinter according to Japanese Patent Application Publication No.11-20194, and the inkjet recording apparatus according to JapanesePatent Application Publication No. 11-48491, a measuring device, such asa dissolved oxygen meter, for measuring the amount of dissolved gas inthe ink is not provided, and therefore it is not possible to ascertainthe amount of dissolved gas in the ink inside the apparatus.

SUMMARY OF THE INVENTION

The present invention has been contrived in view of such circumstances,and an object thereof is to provide an image forming apparatus and aliquid control method, whereby the amount of dissolved gas in the inkinside the recording head is ascertained and maintenance of the ink,such as deaeration, is carried out accordingly.

In order to attain the aforementioned object, the present invention isdirected to an image forming apparatus, comprising: a recording headwhich discharges droplets of liquid onto a recording medium; a dissolvedgas amount estimating device which estimates an amount of dissolved gascontained in the liquid inside the recording head; and a liquidrestoring device which carries out restoration processing of the liquidinside the recording head, if an estimated value of the amount of thedissolved gas estimated by the dissolved gas amount estimating deviceexceeds a prescribed reference value.

According to the present invention, since a dissolved gas amountestimating device is provided which estimates the amount of dissolvedgas contained in the liquid inside the recording head and sincerestoration processing of the liquid inside the recording head iscarried out on the basis of the estimation results from the dissolvedgas amount estimating device, it is possible to prevent dischargeabnormalities caused by air bubbles forming in the ink inside therecording head, and hence a desirable discharge operation can beperformed.

Furthermore, it is not necessary to provide a measuring device(dissolved oxygen meter, or the like) for measuring the amount ofdissolved gas, and consequently, the device can be made more compact.

Moreover, “recording medium” represents a medium onto which liquiddroplets are discharged from a recording head, and more specifically,this term includes various types of media, irrespective of material andsize, such as continuous paper, cut paper, sealed paper or other typesof paper, resin sheets, such as OHP sheets, film, cloth, and othermaterials.

Furthermore, the liquid represents various types of liquids which may bedischarged from discharge holes, such as water, a chemical, processingliquid, ink, or the like.

In one mode for estimating the amount of dissolved gas contained in theliquid by means of the dissolved gas amount estimating device, theamount of dissolved gas is determined on the basis of the gasdissolution rate in the liquid flow path and the flow rate of the liquidinside the liquid flow path.

The restoration processing carried out by the liquid restoring devicemay include a mode where deaeration is performed in order to remove thedissolved gas from the liquid inside the recording head by means of adeaerating device, such as a deaerator, or a mode where the liquid ispurged by discharging or expelling the liquid from discharge holesprovided in the recording head, or the liquid inside the recording headis suctioned by means of a suction device, such as a pump, whereupon newliquid is supplied to the interior of the recording head.

Desirably, if the estimated value of the amount of dissolved gas exceedsa reference value during printing, then the printing operation is haltedand restoration processing is carried out.

Preferably, the image forming apparatus further comprises: a dissolvedgas amount measuring device which measures an amount of the dissolvedgas contained in the liquid supplied to the recording head, thedissolved gas amount measuring device being disposed on an upstream sideof the recording head with respect to a flow direction of the liquid,wherein the liquid restoring device carries out the restorationprocessing of the liquid inside the recording head, if a measured valueof the amount of the dissolved gas measured by the dissolved gas amountmeasuring device exceeds the reference value.

According to the present invention, the dissolved gas amount measuringdevice that measures the amount of the dissolved gas contained in theliquid is provided on the upstream side of the recording head withrespect to the flow direction of the liquid, and if the dissolved gasamount measured by this dissolved gas amount measuring device exceeds areference value, then restoration processing of the ink inside therecording head is carried out.

Since the amount of dissolved gas in the liquid in the vicinity of therecording head can be measured by the dissolved gas amount measuringdevice, it is possible to determine abnormalities in the liquidrestoring device, and it is also possible to ascertain the amount ofdissolved gas in the liquid, accurately. Furthermore, the dissolved gasamount measuring device may include a dissolved oxygen meter formeasuring the amount of oxygen dissolved in the liquid.

In other words, if a dissolved gas amount measuring device for measuringthe actual amount of dissolved gas is provided on the upstream side ofthe recording head, then restoration processing of the liquid is carriedout in cases where an estimated value based on this dissolved gas amountmeasurement exceeds a reference value.

Preferably, the image forming apparatus further comprises: a dissolvedgas amount measuring device which measures an amount of the dissolvedgas contained in the liquid sent from the recording head, the dissolvedgas amount measuring device being disposed on a downstream side of therecording head with respect to a flow direction of the liquid, wherein,if the estimated value does not exceed the reference value, the liquidrestoring device does not carry out restoration processing of the liquidinside the recording head even in cases where a measured value of theamount of the dissolved gas measured by the dissolved gas amountmeasuring device does exceed the reference value.

According to the present invention, if the dissolved gas amountestimated by the dissolved gas amount estimating device does not exceedthe reference value, even in cases where the measurement value of thedissolved gas amount measuring device does exceed the reference value,restoration processing of the liquid inside the recording head is notcarried out, and consequently, the liquid is not consumed wastefully.

Preferably, the liquid restoring device includes a deaerating devicewhich removes at least a portion of the dissolved gas contained in theliquid inside the recording head. According to this, since thedeaerating device is provided for removing the dissolved gas containedin the liquid, the liquid supplied to the recording head is subjected toprescribed deaeration processing.

The deaerating device is preferably disposed on the upstream side of therecording head with respect to the flow of the liquid, in order to carryout deaeration processing of the liquid supplied to the recording head.Furthermore, desirably, the distance between the deaerating device andthe recording head is shortened.

Preferably, the liquid restoring device includes a liquid expellingdevice which expels the liquid inside the recording head to outside ofthe recording head through discharge holes provided in the recordinghead. According to this, since liquid having a dissolved gas contentexceeding the reference value is expelled to the outside of therecording head, it is possible to supply new liquid to the recordinghead.

It is also possible to combine the expulsion of the liquid by theexpelling device and the deaeration processing by the deaerating device.

Modes for expelling the liquid to the outside of the recording headinclude a mode where the liquid is purged by discharging the liquid fromthe recording head onto a maintenance member, such as a cap (preliminarydischarge, blank discharge dummy discharge, or the like), or a modewhere the liquid inside the recording head is suctioned by means of asuction device, such as a pump.

Preferably, the image forming apparatus further comprises: a liquidsupply device which stores the liquid supplied to the recording head; adissolved gas amount measuring device which measures an amount of thedissolved gas contained in the liquid sent from the recording head, thedissolved gas amount measuring device being disposed on a downstreamside of the recording head with respect to a flow direction of theliquid; and a circulation path provided with the dissolved gas amountmeasuring device, the liquid circulating from the recording head throughthe circulation path to the liquid supply device, wherein: the liquidrestoring device includes a deaerating device which removes at least aportion of the dissolved gas contained in the liquid, the deaeratingdevice being disposed on a downstream side of the liquid supply devicewith respect to the flow direction of the liquid; and if the estimatedvalue exceeds the reference value, then the liquid restoring devicecirculates the liquid inside the recording head to the liquid supplydevice through the circulation path, and carries out deaerationprocessing of the liquid supplied to the recording head using thedeaerating device in such a manner that a measured value of the amountof the dissolved gas measured by the dissolved gas amount measuringdevice becomes equal to or less than the reference value.

According to the present invention, if the amount of the dissolved gascontained in the liquid inside the recording head exceeds the referencevalue, then the liquid inside the recording head is circulated throughthe circulation path and the liquid supplied to the recording head issubjected to deaeration processing. Therefore, no wastage of the liquidoccurs.

Furthermore, since the dissolved gas amount measuring device ispositioned on the downstream side of the recording head with respect tothe flow direction of the liquid, and since the amount of dissolved gasin the liquid sent from the recording head can be measured, thenprovided that deaeration processing is carried out in such a manner thatthe measurement value becomes equal to or less than the reference value,the amount of dissolved gas in the liquid inside the recording head willnever exceed the reference value.

Preferably, the image forming apparatus further comprises: a liquidsupply device which stores the liquid supplied to the recording head;and a dissolved gas amount measuring device which measures an amount ofthe dissolved gas contained in the liquid supplied to the recordinghead, wherein: the liquid restoring device includes a liquid expellingdevice which expels the liquid inside the recording head to outside ofthe recording head through discharge holes provided in the recordinghead, and a deaerating device which removes at least a portion of thedissolved gas contained in the liquid, the deaerating device beingdisposed on a downstream side of the liquid supply device with respectto the flow direction of the liquid; the dissolved gas amount measuringdevice is disposed on a downstream side of the deaerating device withrespect to the flow direction of the liquid; the recording head isdisposed on a downstream side of the dissolved gas amount measuringdevice with respect to the flow direction of the liquid; and if theestimated value exceeds the reference value, then the liquid restoringdevice expels the liquid inside the recording head to the outside of therecording head by means of the liquid expelling device, measures theamount of the dissolved gas contained in the liquid supplied from theliquid supply device to the recording head by the dissolved gas amountmeasuring device, and carries out deaeration processing using thedeaerating device in such a manner that a measured value of the amountof the dissolved gas measured by the dissolved gas amount measuringdevice becomes equal to or less than the reference value.

If a device for measuring the amount of dissolved gas is provided on thedownstream side of the recording head, then restoration processing ofthe liquid inside the print head is carried out on the basis of theestimated value of the dissolved gas amount estimated by the dissolvedgas amount estimating device.

Preferably, the image forming apparatus further comprises: a recordinghead temperature adjusting device which adjusts a maintenancetemperature of the recording head; and a recording head temperatureadjustment control device which implements control in such a manner thatthe maintenance temperature of the recording head is lowered using therecording head temperature adjustment device, if the estimated value hasapproached the reference value. According to this, since control isimplemented in such a manner that the maintenance temperature of therecording head is lowered before the amount of dissolved gas in theliquid inside the recording head reaches the reference value, then it ispossible to suppress the occurrence of air bubbles in the liquid insidethe recording head.

Preferably, the dissolved gas amount estimating device estimates theamount of the dissolved gas contained in the liquid according to atravel time of the liquid moving along a liquid flow path. The traveltime of the liquid can be calculated on the basis of the composition ofthe liquid flow path (such as the length of the flow path and the numberof joints in the flow path), the discharge amount and discharge periodof the liquid discharged from the recording head, the amount of liquidconsumed, the use frequency of the recording head, and the like.

Moreover, in order to attain the aforementioned object, the presentinvention is also directed to a liquid control method for an imageforming apparatus including a recording head which discharges dropletsof liquid onto a recording medium, the method comprising the steps of:estimating an amount of dissolved gas contained in the liquid inside therecording head; and carrying out restoration processing of the liquidinside the recording head, if an estimated value of the amount of thedissolved gas estimated in the estimating step exceeds a prescribedreference value.

According to the present invention, a dissolved gas amount estimatingdevice is provided which estimates the amount of dissolved gas containedin the liquid inside the recording head, and if the estimated amount ofdissolved gas exceeds a prescribed reference value, then restorationprocessing of the liquid, such as deaeration processing or purging, iscarried out with respect to the liquid inside the recording head.Consequently, the amount of dissolved gas in the liquid inside therecording head is controlled in such a manner that it becomes equal toor less than the reference value, and therefore, it is possible tosuppress the occurrence of air bubbles in the liquid inside therecording head and to prevent discharge abnormalities caused by theoccurrence of air bubbles.

BRIEF DESCRIPTION OF THE DRAWINGS

The nature of this invention, as well as other objects and advantagesthereof, will be explained in the following with reference to theaccompanying drawings, in which like reference characters designate thesame or similar parts throughout the figures and wherein:

FIG. 1 is a general schematic drawing of an inkjet recording apparatusaccording to an embodiment of the present invention;

FIG. 2 is a plan view of principal components of an area around aprinting unit of inkjet recording apparatus in FIG. 1;

FIG. 3A is a perspective plan view showing an example of theconfiguration of the print head, FIG. 3B is an enlarged view of aportion thereof, and FIG. 3C is a perspective plan view showing anotherexample of the configuration of the print head;

FIG. 4 is a cross-sectional view along a line 4-4 in FIGS. 3A and 3B;

FIG. 5 is a schematic drawing showing the configuration of the inksupply system in the inkjet recording apparatus;

FIG. 6 is a conceptional diagram showing the composition of a deaeratorin the inkjet recording apparatus;

FIG. 7 is a block diagram of the principal components showing the systemconfiguration of the inkjet recording apparatus;

FIG. 8 is a block diagram showing the composition of an ink supplysystem according to the first embodiment;

FIG. 9 is a graph showing the relationship between the amount ofdissolved gas and the travel time of the ink;

FIG. 10 is a compositional diagram showing one example of a constituentmember of the ink supply system shown in FIG. 8;

FIG. 11 is a flowchart showing a sequence of deaeration control relatingto the first embodiment;

FIG. 12 is a block diagram showing the composition of an ink supplysystem according to the second embodiment; and

FIG. 13 is a flowchart showing a sequence of deaeration control relatingto the second embodiment.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

General Configuration of an Inkjet Recording Apparatus

FIG. 1 is a general schematic drawing of an inkjet recording apparatusaccording to an embodiment of the present invention. As shown in FIG. 1,the inkjet recording apparatus 10 comprises: a printing unit 12 having aplurality of print heads 12K, 12C, 12M, and 12Y for ink colors of black(K), cyan (C), magenta (M), and yellow (Y), respectively; an inkstoring/loading unit 14 for storing inks to be supplied to the printheads 12K, 12C, 12M, and 12Y; a paper supply unit 18 for supplyingrecording paper 16; a decurling unit 20 for removing curl in therecording paper 16; a suction belt conveyance unit 22 disposed facingthe nozzle face (ink-droplet ejection face) of the print unit 12, forconveying the recording paper 16 while keeping the recording paper 16flat; a print determination unit 24 for reading the printed resultproduced by the printing unit 12; and a paper output unit 26 foroutputting image-printed recording paper (printed matter) to theexterior.

In FIG. 1, a single magazine for rolled paper (continuous paper) isshown as an example of the paper supply unit 18; however, a plurality ofmagazines with paper differences such as paper width and quality may bejointly provided. Moreover, paper may be supplied with a cassette thatcontains cut paper loaded in layers and that is used jointly or in lieuof a magazine for rolled paper.

In the case of a configuration in which a plurality of types ofrecording paper can be used, it is preferable that an informationrecording medium such as a bar code and a wireless tag containinginformation about the type of paper is attached to the magazine, and byreading the information contained in the information recording mediumwith a predetermined reading device, the type of paper to be used isautomatically determined, and ink-droplet ejection is controlled so thatthe ink-droplets are ejected in an appropriate manner in accordance withthe type of paper.

The recording paper 16 delivered from the paper supply unit 18 retainscurl due to having been loaded in the magazine. In order to remove thecurl, heat is applied to the recording paper 16 in the decurling unit 20by a heating drum 30 in the direction opposite from the curl directionin the magazine. The heating temperature at this time is preferablycontrolled so that the recording paper 16 has a curl in which thesurface on which the print is to be made is slightly round outward.

In the case of the configuration in which roll paper is used, a cutter(first cutter) 28 is provided as shown in FIG. 1, and the continuouspaper is cut into a desired size by the cutter 28. The cutter 28 has astationary blade 28A, whose length is equal to or greater than the widthof the conveyor pathway of the recording paper 16, and a round blade28B, which moves along the stationary blade 28A. The stationary blade28A is disposed on the reverse side of the printed surface of therecording paper 16, and the round blade 28B is disposed on the printedsurface side across the conveyor pathway. When cut paper is used, thecutter 28 is not required.

The decurled and cut recording paper 16 is delivered to the suction beltconveyance unit 22. The suction belt conveyance unit 22 has aconfiguration in which an endless belt 33 is set around rollers 31 and32 so that the portion of the endless belt 33 facing at least the nozzleface of the printing unit 12 and the sensor face of the printdetermination unit 24 forms a horizontal plane (flat plane).

The belt 33 has a width that is greater than the width of the recordingpaper 16, and a plurality of suction apertures (not shown) are formed onthe belt surface. A suction chamber 34 is disposed in a position facingthe sensor surface of the print determination unit 24 and the nozzlesurface of the printing unit 12 on the interior side of the belt 33,which is set around the rollers 31 and 32, as shown in FIG. 1; and thesuction chamber 34 provides suction with a fan 35 to generate a negativepressure, and the recording paper 16 is held on the belt 33 by suction.The belt 33 is driven in the clockwise direction in FIG. 1 by the motiveforce of a motor (not shown in FIG. 1, but shown as a motor 88 in FIG.7) being transmitted to at least one of the rollers 31 and 32, which thebelt 33 is set around, and the recording paper 16 held on the belt 33 isconveyed from left to right in FIG. 1.

Since ink adheres to the belt 33 when a marginless print job or the likeis performed, a belt-cleaning unit 36 is disposed in a predeterminedposition (a suitable position outside the printing area) on the exteriorside of the belt 33. Although the details of the configuration of thebelt-cleaning unit 36 are not depicted, examples thereof include aconfiguration in which the belt 33 is nipped with a cleaning roller suchas a brush roller and a water absorbent roller, an air blowconfiguration in which clean air is blown onto the belt 33, or acombination of these. In the case of the configuration in which the belt33 is nipped with the cleaning roller, it is preferable to make the linevelocity of the cleaning roller different than that of the belt 33 toimprove the cleaning effect.

The inkjet recording apparatus 10 can comprise a roller nip conveyancemechanism, in which the recording paper 16 is pinched and conveyed withnip rollers, instead of the suction belt conveyance unit 22. However,there is a drawback in the roller nip conveyance mechanism that theprint tends to be smeared when the printing area is conveyed by theroller nip action because the nip roller makes contact with the printedsurface of the paper immediately after printing. Therefore, the suctionbelt conveyance in which nothing comes into contact with the imagesurface in the printing area is preferable.

A heating fan 40 is disposed on the upstream side of the printing unit12 in the conveyance pathway formed by the suction belt conveyance unit22. The heating fan 40 blows heated air onto the recording paper 16 toheat the recording paper 16 immediately before printing so that the inkdeposited on the recording paper 16 dries more easily.

As shown in FIG. 2, the printing unit 12 forms a so-called fill-linehead in which a line head having a length that corresponds to themaximum paper width is disposed in the main scanning directionperpendicular to the delivering direction of the recording paper 16(hereinafter referred to as the paper conveyance direction) representedby the arrow in FIG. 2, which is substantially perpendicular to a widthdirection of the recording paper 16. A specific structural example isdescribed later, each of the print heads 12K, 12C, 12M, and 12Y iscomposed of a line head, in which a plurality of ink-droplet ejectionapertures (nozzles) are disposed along a length that exceeds at leastone side of the maximum-size recording paper 16 intended for use in theinkjet recording apparatus 10, as shown in FIG. 2.

The print heads 12K, 12C, 12M, and 12Y are disposed in this order fromthe upstream side along the paper conveyance direction. A color printcan be formed on the recording paper 16 by ejecting the inks from theprint heads 12K, 12C, 12M, and 12Y, respectively, onto the recordingpaper 16 while conveying the recording paper 16.

Although the configuration with the KCMY four standard colors isdescribed in the present embodiment, combinations of the ink colors andthe number of colors are not limited to those, and light and/or darkinks can be added as required. For example, a configuration is possiblein which print heads for ejecting light-colored inks such as light cyanand light magenta are added. Moreover, a configuration is possible inwhich a single print head adapted to record an image in the colors ofCMY or KCMY is used instead of the plurality of print heads for therespective colors.

The print unit 12, in which the full-line heads covering the entirewidth of the paper are thus provided for the respective ink colors, canrecord an image over the entire surface of the recording paper 16 byperforming the action of moving the recording paper 16 and the printunit 12 relatively to each other in the sub-scanning direction just once(i.e., with a single sub-scan). Higher-speed printing is thereby madepossible and productivity can be improved in comparison with a shuttletype head configuration in which a print head reciprocates in the mainscanning direction.

As shown in FIG. 1, the ink storing/loading unit 14 has tanks forstoring the inks to be supplied to the print heads 12K, 12C, 12M, and12Y, and the tanks are connected to the print heads 12K, 12C, 12M, and12Y through channels (not shown), respectively. The ink storing/loadingunit 14 has a warning device (e.g., a display device, an alarm soundgenerator) for warning when the remaining amount of any ink is low, andhas a mechanism for preventing loading errors among the colors.

The print determination unit 24 has an image sensor for capturing animage of the ink-droplet deposition result of the print unit 12, andfunctions as a device to check for ejection defects such as clogs of thenozzles in the print unit 12 from the ink-droplet deposition resultsevaluated by the image sensor.

The print determination unit 24 of the present embodiment is configuredwith at least a line sensor having rows of photoelectric transducingelements with a width that is greater than the ink-droplet ejectionwidth (image recording width) of the print heads 12K, 12C, 12M, and 12Y.This line sensor has a color separation line CCD sensor including a red(R) sensor row composed of photoelectric transducing elements (pixels)disposed in a line provided with an R filter, a green (G) sensor rowwith a G filter, and a blue (B) sensor row with a B filter. Instead of aline sensor, it is possible to use an area sensor composed ofphotoelectric transducing elements which are disposed two-dimensionally.

The print determination unit 24 reads a test pattern printed with theprint heads 12K, 12C, 12M, and 12Y for the respective colors, and theejection of each head is determined. The ejection determination includesthe presence of the ejection, measurement of the dot size, andmeasurement of the dot deposition position. The print determination unit24 is provided with a light source (not shown) to illuminate thedeposited dots.

A post-drying unit 42 is disposed following the print determination unit24. The post-drying unit 42 is a device to dry the printed imagesurface, and includes a heating fan, for example. It is preferable toavoid contact with the printed surface until the printed ink dries, anda device that blows heated air onto the printed surface is preferable.

In cases in which printing is performed with dye-based ink on porouspaper, blocking the pores of the paper by the application of pressureprevents the ink from coming contact with ozone and other substance thatcause dye molecules to break down, and has the effect of increasing thedurability of the print.

A heating/pressurizing unit 44 is disposed following the post-dryingunit 42. The heating/pressurizing unit 44 is a device to control theglossiness of the image surface, and the image surface is pressed with apressure roller 45 having a predetermined uneven surface shape while theimage surface is heated, and the uneven shape is transferred to theimage surface.

The printed matter generated in this manner is outputted from the paperoutput unit 26. The target print (i.e., the result of printing thetarget image) and the test print are preferably outputted separately. Inthe inkjet recording apparatus 10, a sorting device (not shown) isprovided for switching the outputting pathway in order to sort theprinted matter with the target print and the printed matter with thetest print, and to send them to paper output units 26A and 26B,respectively. When the target print and the test print aresimultaneously formed in parallel on the same large sheet of paper, thetest print portion is cut and separated by a cutter (second cutter) 48.The cutter 48 is disposed directly in front of the paper output unit 26,and is used for cutting the test print portion from the target printportion when a test print has been performed in the blank portion of thetarget print. The structure of the cutter 48 is the same as the firstcutter 28 described above, and has a stationary blade 48A and a roundblade 48B.

Although not shown in FIG. 1, a sorter for collecting prints accordingto print orders is provided to the paper output unit 26A for the targetprints.

Next, the structure of the print heads is described. The print heads12K, 12C, 12M, and 12Y provided for the ink colors have the samestructure, and a reference numeral 50 is hereinafter designated to anyof the print heads 12K, 12C, 12M, and 12Y.

FIG. 3A is a perspective plan view showing an example of a configurationof a print head, FIG. 3B is a partial enlarged view of FIG. 3A, FIG. 3Cis a perspective plan view showing another example of the configurationof the print head, and FIG. 4 is a cross-sectional view taken along theline 4-4 in FIGS. 3A and 3B, showing the inner structure of an inkchamber unit. The nozzle pitch in the print head 50 should be minimizedin order to maximize the density of the dots printed on the surface ofthe recording paper. As shown in FIGS. 3A, 3B, 3C and 4, the print head50 in the present embodiment has a structure in which a plurality of inkchamber units 53 including nozzles 51 for ejecting ink-droplets andpressure chambers 52 connecting to the nozzles 51 are disposed in theform of a staggered matrix, and the effective nozzle pitch is therebymade small.

As shown in FIGS. 3A and 3B, the print head 50 in the present embodimentis a full-line head in which one or more of nozzle rows in which the inkdischarging nozzles 51 are disposed along a length corresponding to theentire width of the recording medium in the direction substantiallyperpendicular to the conveyance direction of the recording medium.

Alternatively, as shown in FIG. 3C, a full-line head can be composed ofa plurality of short two-dimensionally arrayed head units 50′ disposedin the form of a staggered matrix and combined so as to form nozzle rowshaving lengths that correspond to the entire width of the recordingpaper 16.

The planar shape of the pressure chamber 52 provided for each nozzle 51is substantially a square, and the nozzle 51 and an inlet of suppliedink (supply port) 54 are disposed in both corners on a diagonal line ofthe square. Each pressure chamber 52 is connected to a common channel(not shown) through the supply port 54.

An actuator 58 having a discrete electrode 57 is joined to a pressureplate 57, which forms the ceiling of the pressure chamber 52, and theactuator 58 is deformed by applying drive voltage to the discreteelectrode 57 to eject ink from the nozzle 51. When ink is ejected, newink is delivered from the common flow channel 55 through the supply port54 to the pressure chamber 52.

The plurality of ink chamber units 53 having such a structure aredisposed in a grid with a fixed pattern in the line-printing directionalong the main scanning direction and in the diagonal-row directionforming a fixed angle θ that is not a right angle with the main scanningdirection. With the structure in which the plurality of rows of inkchamber units 53 are disposed at a fixed pitch d in the direction at theangle θ with respect to the main scanning direction, the nozzle pitch Pas projected in the main scanning direction is d×cos θ.

Hence, the nozzles 51 can be regarded to be equivalent to those disposedat a fixed pitch P on a straight line along the main scanning direction.Such configuration results in a nozzle structure in which the nozzle rowprojected in the main scanning direction has a high nozzle density of upto 2,400 nozzles per inch (npi).

In the implementation of the present invention, the structure of thenozzle disposement is not particularly limited to the examples shown inthe drawings. Moreover, the present embodiment adopts the structure thatejects ink-droplets by deforming the actuator 58 such as a piezoelectricelement; however, the implementation of the present invention is notparticularly limited to this. Instead of the piezoelectric inkjetmethod, various methods may be adopted including a thermal inkjet methodin which ink is heated by a heater or another heat source to generatebubbles, and ink-droplets are ejected by the pressure thereof.

FIG. 5 is a schematic drawing showing the configuration of the inksupply system in the inkjet recording apparatus 10.

An ink bottle 60 is a base tank that supplies ink and is set in the inkstoring/loading unit 14 described with reference to FIG. 1. The aspectsof the ink bottle 60 include a refillable type and a cartridge type:when the remaining amount of ink is low, the ink bottle 60 of therefillable type is filled with ink through a filling port (not shown)and the ink bottle 60 of the cartridge type is replaced with a new one.In order to change the ink type in accordance with the intendedapplication, the cartridge type is suitable, and it is preferable torepresent the ink type information with a bar code or the like on thecartridge, and to perform ejection control in accordance with the inktype.

As shown in FIG. 5, the ink bottle 60 is connected to a sub tank 61 viaan ink supply path, and a deaerator 62 is provided between the sub tank61 and the print head 50 in order to remove gas (air bubble) dissolvedin the ink. Furthermore, a filter (not illustrated) for removing foreignmatter, and the like, from the ink is provided between the sub tank 61and the deaerator 62. The filter mesh size in the filter 62 ispreferably equivalent to or less than the diameter of the nozzle andcommonly about 20 μm.

The sub tank 61 has a damper function for preventing variation in theinternal pressure of the head and a function for improving refilling ofthe print head. Possible modes for controlling the internal pressure bymeans of the sub tank 61 are: a mode where the internal pressure of theink chamber unit 53 is controlled by the differential in the ink levelbetween a sub tank which is open to the external air and the ink chamberunits inside the print head 50; and a mode where the internal pressureof the sub tank and the ink chambers is controlled by a pump connectedto a sealed sub tank; and the like. Either of these modes may beadopted.

Furthermore, a dissolved oxygen meter 63 is provided for measuring theamount of dissolved gas contained in the unused ink inside the printhead 50, and after the amount of dissolved gas has been measured by thedissolved oxygen meter 63, the unused ink inside the print head 50 issupplied to the sub tank 61. In this way, an ink circulation channel isformed from the print head 50 to the sub tank 61 via the dissolvedoxygen meter 63 (this circulation channel is not illustrated in FIG. 5and is indicated by reference symbol 100 in FIG. 8).

The inkjet recording apparatus 10 is also provided with a cap 64 as adevice to prevent the nozzle 51 from drying out or to prevent anincrease in the ink viscosity in the vicinity of the nozzles, and acleaning blade 66 as a device to clean the nozzle face. A maintenanceunit including the cap 64 and the cleaning blade 66 can be moved in arelative fashion with respect to the print head 50 by a movementmechanism (not shown), and is moved from a predetermined holdingposition to a maintenance position below the print head 50 as required.

The cap 64 is displaced up and down in a relative fashion with respectto the print head 50 by an elevator mechanism (not shown). When thepower of the inkjet recording apparatus 10 is switched OFF or when in aprint standby state, the cap 64 is raised to a predetermined elevatedposition so as to come into close contact with the print head 50, andthe nozzle face is thereby covered with the cap 64.

The cleaning blade 66 is composed of rubber or another elastic member,and can slide on the ink discharge surface (surface of the nozzle plate)of the print head 50 by means of a blade movement mechanism (not shown).When ink droplets or foreign matter has adhered to the nozzle plate, thesurface of the nozzle plate is wiped, and the surface of the nozzleplate is cleaned by sliding the cleaning blade 66 on the nozzle plate.

During printing or standby, when the frequency of use of specificnozzles is reduced and ink viscosity increases in the vicinity of thenozzles, a preliminary discharge is made toward the cap 64 to dischargethe degraded ink.

Also, when bubbles have become intermixed in the ink inside the printhead 50 (inside the pressure chamber), the cap 64 is placed on the printhead 50, ink (ink in which bubbles have become intermixed) inside thepressure chamber is removed by suction with a suction pump 67, and thesuction-removed ink is sent to a collection tank 68. This suction actionentails the suctioning of degraded ink whose viscosity has increased(hardened) when initially loaded into the head, or when service hasstarted after a long period of being stopped.

When a state in which ink is not discharged from the print head 50continues for a certain amount of time or longer, the ink solvent in thevicinity of the nozzles 51 evaporates and ink viscosity increases. Insuch a state, ink can no longer be discharged from the nozzle 51 even ifthe actuator 59 is operated. Before reaching such a state the actuator59 is operated (in a viscosity range that allows discharge by theoperation of the actuator 59), and the preliminary discharge is madetoward the ink receptor to which the ink whose viscosity has increasedin the vicinity of the nozzle is to be discharged. After the nozzlesurface is cleaned by a wiper such as the cleaning blade 66 provided asthe cleaning device for the nozzle face, a preliminary discharge is alsocarried out in order to prevent the foreign matter from becoming mixedinside the nozzles 51 by the wiper sliding operation. The preliminarydischarge is also referred to as “dummy discharge”, “purge”, “liquiddischarge”, and so on.

When bubbles have become intermixed in the ink inside the nozzle 51 andthe pressure chamber 52, ink can no longer be discharged from thenozzles even if the actuator 58 is operated. Also, when the inkviscosity inside the nozzle 51 has increased over a certain level, inkcan no longer be discharged from the nozzle 51 even if the actuator 58is operated. In these cases, a suctioning device to remove the inkinside the pressure chamber 52 by suction with a suction pump, or thelike, is placed on the nozzle face of the print head 50, and the ink inwhich bubbles have become intermixed or the ink whose viscosity hasincreased is removed by suction.

However, this suction action is performed with respect to all the ink inthe pressure chamber 52, so that the amount of ink consumption isconsiderable. Therefore, a preferred aspect is one in which apreliminary discharge is performed when the increase in the viscosity ofthe ink is small.

FIG. 6 is a conceptional diagram showing the structure of the deaerator62 illustrated in FIG. 5.

The deaerator 62 comprises an ink flow channel 62B provided with ahollow fiber bundle which is gas-permeable, such as a fluorine-basedtube or silicon-based tube, in a deaerating region 62A. The ink arrivingfrom the sub tank 61 is subjected to deaeration at reduced pressure whenit passes through the ink flow channel 62B, whereupon it is supplied tothe print head 50.

In the reduced pressure deaeration process, if the pressure of thedeaerating region 62A is reduced by means of a vacuum pump 62C, then thegas dissolved inside the ink is removed from the ink due to the actionof the negative pressure acting on the outer circumference of the inkflow channel 62B, and the separated gas is discharged into theatmosphere via the vacuum pump 62C. Moreover, the deaerator 62 alsocomprises a vacuum gauge 62D in order to monitor the pressure (level ofvacuum) inside the deaerating region.

A commonly known technique, such as the vacuum (reduced pressuredeaeration) method described above can be used for deaerating the ink inthe deaerator 62, and various other methods, such as an ultrasonicvibration method or a centrifugal separation method, may also be used.

FIG. 7 is a block diagram of the principal components showing the systemconfiguration of the inkjet recording apparatus 10. The inkjet recordingapparatus 10 has a communication interface 70, a system controller 72,an image memory 74, a motor driver 76, a heater driver 78, a printcontroller 80, an image buffer memory 82, a head driver 84, and othercomponents.

The communication interface 70 is an interface unit for receiving imagedata sent from a host computer 86. A serial interface such as USB,IEEE1394, Ethernet, wireless network, or a parallel interface such as aCentronics interface may be used as the communication interface 70. Abuffer memory (not shown) may be mounted in this portion in order toincrease the communication speed. The image data sent from the hostcomputer 86 is received by the inkjet recording apparatus 10 through thecommunication interface 70, and is temporarily stored in the imagememory 74. The image memory 74 is a storage device for temporarilystoring images inputted through the communication interface 70, and datais written and read to and from the image memory 74 through the systemcontroller 72. The image memory 74 is not limited to memory composed ofa semiconductor element, and a hard disk drive or another magneticmedium may be used.

The system controller 72 controls the communication interface 70, imagememory 74, motor driver 76, heater driver 78, and other components. Thesystem controller 72 has a central processing unit (CPU), peripheralcircuits therefor, and the like. The system controller 72 controlscommunication between itself and the host computer 86, controls readingand writing from and to the image memory 74, and performs otherfunctions, and also generates control signals for controlling a heater89 and the motor 88 in the conveyance system.

The motor driver (drive circuit) 76 drives the motor 88 in accordancewith commands from the system controller 72. The heater driver (drivecircuit) 78 drives the heater 89 of the post-drying unit 42 or the likein accordance with commands from the system controller 72.

The print controller 80 has a signal processing function for performingvarious tasks, compensations, and other types of processing forgenerating print control signals from the image data stored in the imagememory 74 in accordance with commands from the system controller 72 soas to apply the generated print control signals (print data) to the headdriver 84. Required signal processing is performed in the printcontroller 80, and the ejection timing and ejection amount of theink-droplets from the print head 50 are controlled by the head driver 84on the basis of the image data. Desired dot sizes and dot placement canbe brought about thereby.

The print controller 80 is provided with the image buffer memory 82; andimage data, parameters, and other data are temporarily stored in theimage buffer memory 82 when image data is processed in the printcontroller 80. The aspect shown in FIG. 7 is one in which the imagebuffer memory 82 accompanies the print controller 80; however, the imagememory 74 may also serve as the image buffer memory 82. Also possible isan aspect in which the print controller 80 and the system controller 72are integrated to form a single processor.

The head driver 84 drives actuators for the print heads 12K, 12C, 12M,and 12Y of the respective colors on the basis of the print data receivedfrom the print controller 80. A feedback control system for keeping thedrive conditions for the print heads constant may be included in thehead driver 84.

The inkjet recording apparatus 10 comprises an ink control functionwhereby the amount of dissolved gas contained in the ink is equal to orless than a prescribed value. The details of this function are describedbelow, but the amount of dissolved gas in the ink inside the print head50 is estimated by the system controller 72, and if this estimate amountof dissolved gas exceeds a prescribed value, then the system controller72 implements control whereby the ink inside the print head 50 iscirculated to the deaerator 62, the ink is subjected to deaerationprocessing in the deaerator 62, and the deaerated ink is then suppliedto the print head 50.

The amount of dissolved gas in the ink circulated from the print head 50to the sub tank 61 is measured by a dissolved oxygen meter 63. Thismeasurement result is sent to the system controller 72, which comparesthe amount of dissolved gas in the ink with a specified value, and ifthe amount of dissolved gas exceeds this specified value, then thesystem controller 72 activates the deaerator 62 and further deaerationof the ink is performed.

Here, the gas measured by the dissolved oxygen meter includes variousother gases which may be dissolved in the ink, and not only oxygen.

First Embodiment

Next, the ink control method and deaeration process control in an inkjetrecording apparatus 10 according to a first embodiment of the presentinvention will be described.

Generally, in an inkjet recording apparatus, there is significant lossin the pressure applied to the ink if air bubbles become mixed into theink chamber unit 53 illustrated in FIGS. 3A to 3C and FIG. 4, and thiscan give rise to discharge abnormalities.

Discharge abnormalities of this kind give rise to image deterioration,such as streaking or color irregularities, in the printed image, andthus cause a marked decline in printing quality. Therefore, in order toprevent image deterioration of this kind, deaerated ink may be used insuch a manner that the amount of dissolved gas in the ink is equal to orless than a specified value.

The inkjet recording apparatus 10 is composed in such a manner that theamount of dissolved gas in the ink inside the print head 50 is estimatedand deaeration processing is carried out on the basis of this estimatedvalue. Within the print head 50, it is not possible to circulate the inkin the nozzles 51 and pressure chambers 52 (in other words, the ink onthe downstream side beyond the common flow channel), and therefore,desirably, the ink is expelled (discharged) to the outside of the printhead 50 during the deaeration process.

FIG. 8 is a block diagram showing an isolated view of the portion of theink supply system in the inkjet recording apparatus 10 illustrated inFIG. 5 which relates to deaeration processing. In FIG. 8, the arrowsindicate the direction of the flow of ink.

As shown in FIG. 5, the ink stored in the ink bottle 60 is supplied tothe print head 50 via the sub tank 61 and the deaerator 62. Furthermore,unused ink in the print head 50 is returned to the sub tank 61 bypassing along a circulation channel 100 which includes a dissolvedoxygen meter 63. More specifically, the ink bottle 60, sub tank 61,deaerator 62, print head 50, dissolved oxygen meter 63 and sub tank 61are positioned, in this order, from the upstream side of the flow path.If the sub tank 61 is omitted, then a circulation channel 100 includinga dissolved oxygen meter 63 is formed between the print head 50 and theink bottle 60. Desirably, a sub tank 61 is provided in order to controlthe internal pressure of the print head 50 and to ensure refillingcharacteristics.

Furthermore, in the split type head illustrated in FIG. 3C, desirably, adeaerator 62, a dissolved oxygen meter 63 and a circulation channel 100are provided separately in each of the split heads. If a deaerator 62, adissolved oxygen meter 63 and a circulation channel 100 are provided ineach head, then if the respective heads have different duties, it ispossible to optimize the amount of dissolved gas inside each head,independently.

The amount of dissolved gas in the ink inside the print head 50 isestimate from the travel time of the ink from the deaerator 62 to theprint head 50. In this estimation process, a safety ratio of 1 or moreis adopted in order to ensure a suitable margin. Furthermore, it isjudged whether or not to implement further deaeration of the unused inkinside the print head 50, on the basis of the measurement value from thedissolved oxygen meter 63 and the aforementioned estimate amount ofdissolved gas.

The travel time of the ink can be calculated from the product of thedroplet ejection size and the droplet ejection volume during printing,and the product of the droplet ejection size and droplet ejectionvoltage during maintenance.

The ink flow path from the deaerator 62 to the print head 50 isconstituted principally by an ink supply hose and a joint for connectingthis supply hose. Therefore, if the dissolution rate at which gasdissolves into the ink from outside the supply hose and the joint regionis previously known, then the amount of dissolved gas contained in theink inside the print head 50 can be estimate.

More specifically, the relationship between the speed of movement of theink, t, and the amount of dissolved gas in the ink, V, is indicated bythe graph 120 shown in FIG. 9, and the gradient (dV/dt) of this graph120 corresponds to the aforementioned dissolution rate of the gas. Inthe graph 120, V₀ is the initial value of the amount of dissolved gas,which has a different value for each type of ink. Furthermore, Vsatindicates the amount of dissolved gas at saturation, and if this amountof dissolved gas at saturation is exceeded, then air bubbles can form inthe ink.

The ink dissolution rate is expressed by the following formula 1:(dV/dt)=(dV/dt)₁+(dV/dt)₂+(dV/dt)₃+ . . . .  (1)

This ink dissolution rate (dV/dt) varies depending on the members(joints, hose, and the like) forming the ink flow channels, and it alsochanges with the environmental conditions, such as temperature andhumidity. Therefore, as indicated by the formula 1, the dissolution rate(dV/dt) of the gas is expressed as the sum of the gas dissolution rates(dV/dt)₁, (dV/dt)₂, (dV/dt)₃, . . . , derived respectively in accordancewith the component members of the ink flow channels and theenvironmental parameters.

In an ink supply system comprising a joint 200 (joint A), a joint 202(joint B), a supply hose 210 (supply hose C), and a supply hose 212(supply hose D), as shown in FIG. 10, the gas dissolution rate indicatedby the formula 1 will be represented by the following formula 2:(dV/dt)₁=(dV _(A) /dt)+(dV _(B) /dt)+ . . . .  (2)

In other words, (dV/dt)₁ is the gas dissolution rate in the jointregion, and its value is determined on the basis of the number of jointsand the structure of each joint. If the gas dissolution rates at thejoint 200 and the joint 202 are respectively taken to be dV_(A)/dt anddV_(B)/dt, then (dV/dt)₁ is expressed by the sum of dV_(A)/dt anddV_(B)/dt, as shown in the formula 2.

If there are three or more joints, then the gas dissolution rate in thejoint sections (dV/dt)₁ , is expressed by the sum of the gas dissolutionrates at each of the joints.

Furthermore, (dV/dt)₂ is the gas dissolution rate in the supply hosesections and is expressed by the sum of the gas dissolution rates in thehose sections as indicated by the following formula 3:(dV/dt)₂=(dV _(C) /dt)+(dV _(D) /dt)+ . . . .  (3)

If the gas dissolution rates in the supply hose 210 and the supply hose212 are respectively taken to be dV_(C)/dt and dV_(D)/dt, then (dV/dt)₂is expressed by the sum of dV_(C)/dt and dV_(D)/dt, as shown in theformula 3. Similarly to the joint sections, if there are three or moresupply hoses, then the gas dissolution rate in the supply hose sections(dV/dt)₂ is expressed by the sum of the gas dissolution rates in each ofthe joints. The gas dissolution rate in the supply hoses is determinedon the basis of the number of supply hoses, and the material, surfacearea, length, and the like, of each supply hose.

Furthermore, (dV/dt)₃ is the gas dissolution rate according to the gastemperature (ambient temperature).

A data table may be prepared in which the aforementioned gas dissolutionrates are stored as data, this table may be stored in a memory device,such as the memory 74 or the like illustrated in FIG. 7, and the amountof dissolved gas in the ink may be estimate by referring to this datatable. Alternatively, the graphs and formulae shown in FIG. 9 and FIG.10 may be converted into a program, and the amount of dissolved gas inthe ink may be estimate by means of this program.

Desirably, a non-volatile rewriteable memory, such as an EEPROM, is usedas a memory device for recording the data table or the program, in sucha manner that the data table or program can be updated.

If the data table or program is stored in a removable medium, such as amemory card, CD-ROM, or the like, and the data table or program is readin to the device when the power supply of the apparatus is switched on,then it is possible to refer to the most recent data table, at alltimes.

Next, the process of deaeration control in the inkjet recordingapparatus 10 will be described with reference to FIG. 11. FIG. 11 is aflowchart showing the sequence of deaeration control provided in theinkjet recording apparatus 10.

When print data is acquired and printing is started (step S10), then itis judged whether or not the amount of dissolved gas in the ink measuredby the dissolved oxygen meter 63 exceeds a specified value (step S12).

If the measurement value of the dissolved oxygen meter 63 does notexceed the specified value (NO verdict), then the procedure advances tostep S14 and it is judged whether or not the estimate value for theamount of dissolved gas exceeds the specified value.

If it is judged at step S14 that the estimate value for the amount ofdissolved gas does not exceed the specified value (NO verdict), then theprocedure advances to step S16 and printing is continued.

During the printing operation, the end of printing is monitored (stepS18) and if printing has not ended at step S18 (NO verdict), then theprocedure returns to step S12, and the measurement value of thedissolved oxygen meter 63 is monitored.

On the other hand, if it is judged at step S18 that printing of thefinal print data has been completed and that a print completionoperation is to be performed (YES verdict), then the printing control inthe inkjet recording apparatus 10 terminates (step S20).

Furthermore, if it is judged at step S14 that the estimate value for theamount of dissolved gas exceeds the specified value (YES verdict), thenprinting is interrupted and the procedure advances to step S24. At stepS24, the unused ink inside the print head 50 is supplied to thedeaerator 62 via the circulation channel 100 shown in FIG. 8, and theink is subjected to deaeration processing.

Thereupon, the procedure advances to step S26, where the estimate valuefor the amount of dissolved gas is reset, and then proceeds to step S12.

Furthermore, if it is judged at step S12 that the measurement value ofthe dissolved oxygen meter 63 exceeds the specified value, (YESverdict), then the procedure advances to step S22, where it is judgedwhether or not the estimate value for the amount of dissolved gasexceeds the specified value. If the estimate value for the amount ofdissolved gas does not exceed the specified value (NO verdict), then theprocedure advances to step S16 and printing is continued.

If the estimate value for the amount of dissolved gas exceeds thespecified value (YES verdict) at step S22, then the procedure advancesto step S24, and the unused ink inside the print head 50 is sent to thedeaerator 62, where it is subjected to deaeration processing.

In other words, even in cases where the measurement value of thedissolved oxygen meter 63 exceeds the specified value, if the estimatevalue for the amount of dissolved gas does not exceed the specifiedvalue (in other words, if step S14 in FIG. 11 returns a NO verdict),then control is implemented in such a manner that printing continues.

If, on the other hand, the measurement value of the dissolved oxygenmeter 63 exceeds the specified value and the estimate value for theamount of dissolved gas also exceeds the specified value (in otherwords, a YES verdict at step S22), then control is implemented in such amanner that printing is interrupted, the unused ink inside the printhead 50 is returned to the deaerator 62, where it is deaerated, andprinting is not restarted until the level of deaeration (the amount ofdissolved gas in the ink) falls below the specified value.

Here, if the unused ink inside the print head 50 is circulated in orderto deaerate the ink, then it may be impossible to discharge the ink, dueto variation in the internal pressure inside the print head 50.Therefore, printing is interrupted while the ink inside the print head50 is circulated.

Furthermore, it can be seen that a case where the estimate value for theamount of dissolved gas exceeds the specified value, when themeasurement value of the dissolved oxygen meter 63 does not exceed thespecified value, will not normally arise, since a safety ratio of one orabove is adopted when estimating the amount of dissolved gas. In thiscase, there may be a possibility of a temperature change in the printhead 50 and the ink supply system, and therefore control is implementedin such a manner that the ink inside the print head 50 and the inksupply system is deaerated again, and the estimate value for the amountof dissolved gas is reset.

If the same phenomenon occurs after this processing (in other words, ifa YES verdict is returned again at step S22), then a fault in thedissolved oxygen meter 63 can be inferred, and hence control isimplemented in such a manner that an abnormality alarm is generated.

In the ink supply system illustrated in the present example, a dissolvedoxygen meter 63 is provided in the circulation channel 100 from theprint head 50 to the sub tank 61, but if the deaerating capacity of thedeaerator 62 is sufficiently high and the amount of dissolved gascontained in the ink falls to or below a prescribed level, then thedissolved oxygen meter 63 may be omitted.

If the dissolved oxygen meter 63 is omitted, then the amount ofdissolved gas inside the print head 50 is estimate from the travel timeof the ink from the deaerator 62 to the print head 50, and if thisestimate value exceeds a specified value, then the unused ink inside theprint head 50 is returned to the deaerator 62 and deaeration is carriedout again. After further deaeration processing, if the amount ofdissolved gas in the ink has fallen below a specified value, thenprinting is restarted.

If the dissolved oxygen meter 63 is omitted, than step S12 is omittedfrom the flowchart shown in FIG. 11.

In an inkjet recording apparatus 10 having the composition describedabove, the amount of dissolved gas in the print head 50 is estimate by adissolved gas amount estimating device using the system controller 72,or the like, and if the amount of dissolved gas exceeds a specifiedvalue, then the ink including the unused ink inside the print head 50 issent to the deaerator 62 via the circulation channel 100, and issubjected to deaeration processing before being supplied to the printhead 50. Consequently, ink containing an amount of dissolved gas whichis less than the specified value is supplied to the print head 50, andit is therefore possible to prevent discharge abnormalities caused byair bubbles forming in the ink. Furthermore, since maintenanceoperations, such as purging, suction, and the like, can be reduced,there is no occurrence of wasted ink that is consumed duringmaintenance.

Furthermore, if a dissolved oxygen meter 63 is provided in thecirculation channel 100 from the print head 50 to the sub tank 61 (inother words, on the downstream side of the print head 50), then it ispossible to measure, and hence judge, the amount of dissolved gas in theink inside the print head 50. If the deaeration capacity of thedeaerator is sufficiently greater than the maximum flow rate of the ink,then the amount of dissolved gas in the ink that has passed through thedeaerator 62 will assume a certain, uniform saturated state.Consequently, there is no particular requirement to provide a dissolvedoxygen meter 63 and control can be implemented on the basis of anestimate value for the amount of dissolved gas. If no dissolved oxygenmeter 63 is provided, then a problem arises in that it is not possibleto identify an abnormality in the deaerator (for instance, if thecapacity of the vacuum pump is insufficient and the ink does not reachthe required level of deaeration).

Even if a circulating system including a circulation channel 100 isprovided, it is not possible to circulate the ink inside the nozzles 51and the pressure chambers 52 shown in FIG. 4, and therefore purging orsuction should be carried out when the ink is circulated for the purposeof further deaeration.

Second Embodiment

Next, the ink control method and deaeration process control in an inkjetrecording apparatus 10 according to a second embodiment of the presentinvention will be described.

FIG. 12 shows the general configuration of the ink supply system of aninkjet recording apparatus 10 relating to the second embodiment. In FIG.12, items which are the same as or similar to those in FIG. 8 arelabeled with the same reference numerals and description thereof isomitted here.

As shown in FIG. 12, the ink supply system comprises an ink bottle 60,sub tank 61, deaerator 62, dissolved oxygen meter 63 and print head 50,disposed in this order from the upstream side of the ink flow path. Inother words, compared to the ink supply system shown in FIG. 8, thedissolved oxygen meter 63 is positioned on the upstream side of theprint head 50, and the circulation channel 100 is omitted.

FIG. 13 is a flowchart showing the sequence of deaeration control in aninkjet recording apparatus 10 having the ink supply system shown in FIG.12.

When print data is acquired and printing is started (step S100), then itis judged whether or not the amount of dissolved gas in the ink measuredby the dissolved oxygen meter 63 exceeds a specified value (step S102).

If the measurement value of the dissolved oxygen meter 63 does notexceed the specified value (NO verdict), then it is judged whether ornot the estimate value for the amount of dissolved gas exceeds thespecified value (step S104).

If the estimate value for the amount of dissolved gas does not exceedthe specified value in step S104 (NO verdict), then the procedureadvances to step 106, printing is continued, and the end of printing ismonitored (step S108). If printing has not ended in step S108 (NOverdict), then the procedure returns to step S102 and the measurementvalue of the dissolved oxygen meter 63 is monitored.

On the other hand, if it is judged at step S108 that printing of thefinal print data has been completed and that a print completionoperation is to be performed (YES verdict), then the printing control inthe inkjet recording apparatus 10 terminates (step S110).

Furthermore, if it is judged at step S104 that the estimate value forthe amount of dissolved gas exceeds the specified value (YES verdict),then printing is interrupted, the procedure advances to step S112, andrestoration processing, such as purging or suction, is carried out inthe print head 50.

Thereupon, the estimate value for the amount of dissolved gas is reset(step S114), and the procedure advances to step 102.

If, on the other hand, it is judged at step S102 that the estimate valuefor the amount of dissolved gas exceeds the specified value (YESverdict), then the procedure advances to step S112, and restorationprocessing, such as purging or suction, is carried out in the print head50.

In other words, if the measurement value of the dissolved oxygen meter63 exceeds the specified value (namely, in the case of a YES verdict atstep S102 in FIG. 13), control is implemented in such a manner thatprinting is interrupted and restoration processing, such as purging orsuction, is carried out in the print head 50.

Furthermore, if the measurement value of the dissolved oxygen meter 63does not exceed the specified value and the estimate value for theamount of dissolved gas does exceed the specified value (namely, in thecase of a YES verdict at step S104 in FIG. 13), then control isimplemented in such a manner that printing is interrupted andrestoration processing, such as purging or suction, is carried out inthe print head 50. The restoration processing is carried outcontinuously until the amount of dissolved gas has fallen to or belowthe specified value.

If, on the other hand, the measurement value of the dissolved oxygenmeter 63 does not exceed the specified value and the estimate value ofthe amount of dissolved gas does not exceed the specified value either(in other words, a NO verdict at step S104), then normal printing iscontinued.

In the present example, it is possible to omit the dissolved oxygenmeter 63. In this case, if the estimate value for the amount ofdissolved gas has exceeded the specified value, then printing isinterrupted, restoration processing, such as purging or suction, iscarried out, and if the estimate value for the amount of dissolved gasdoes not exceed the specified value, then normal printing is continued.This mode may also be applied in a case where a dissolved oxygen meter63, when a fault has occurred in the dissolved oxygen meter 63.

In the present example, it is possible to adopt a mode in which thedeaerator is omitted. More specifically, since there is no circulationchannel from the print head 50 to the sub tank 61 in the ink supplysystem shown in FIG. 12, then it is not possible to circulate the unusedink inside the print head 50 and carry out further deaeration. In otherwords, if the measurement value of the amount of dissolved gas exceedsthe specified value, then since the ink inside the print head 50 canonly be expelled to outside the print head, it is possible to omit thedeaerator 62 if sufficiently deaerated ink is used. However, even if adeaerator 62 is not used, it is possible to dispose a dissolved oxygenmeter inside the ink flow channel in such a manner that the amount ofdissolved gas inside the print head 50 can be estimate.

In the first embodiment and second embodiment described above, if theestimate value for the amount of dissolved gas approaches the specifiedvalue, then the formation of air bubbles can be prevented by loweringthe maintenance temperature of the print head 50. In general, the lowerthe temperature of a liquid, the greater the amount of gas that can bedissolved in that liquid.

Furthermore, it is preferable to shorten the interval at which dischargefailure detection is performed, since this reduces the possibility of aprinting defect occurring due to a discharge abnormality.

FIG. 11 and FIG. 13 show examples of deaeration control during aprinting operation, but this control sequence may also be applied duringintervals between prints, or when the apparatus is at standby.

In the above-described embodiments, a line head type of print head hasbeen described, which corresponds to the full width of the recordingmedium, but the present invention may also be applied to a serial typeprint head which performs printing by scanning a short print head in thebreadthways direction of the recording medium.

Furthermore, an ink discharge method has been described in which adischarge force is applied to the ink by driving a piezoelectricelement, but it is also possible to adopt a bubble jet method in whichthe ink is heated by a heat source, such as a heating element, therebygenerating a bubble in the ink which applies a discharge force to theink.

The present invention may also be applied to a liquid discharge deviceother than an inkjet recording apparatus, such as a device fordischarging a liquid such as water, processing liquid, or chemical, ontoa discharge receiving medium from nozzles provided in a discharginghead.

The ink control method and the deaeration control method described inthe present embodiments may also be converted into programs and recordedonto a recording device, such as an internal memory or memory card.Furthermore, a recording medium on which the aforementioned programs arerecorded may be distributed.

It should be understood, however, that there is no intention to limitthe invention to the specific forms disclosed, but on the contrary, theinvention is to cover all modifications, alternate constructions andequivalents falling within the spirit and scope of the invention asexpressed in the appended claims.

1. An image forming apparatus comprising: a recording head whichdischarges droplets of liquid onto a recording medium; a dissolved gasamount calculating device which calculates an estimate of an amount ofdissolved gas contained in the liquid located inside the recording head,wherein said calculation is based on properties of the liquid orproperties of the image forming apparatus; a liquid restoring devicewhich carries out restoration processing of the liquid located insidethe recording head, if the estimate of the amount of the dissolved gascalculated by the dissolved gas amount calculating device exceeds aprescribed reference value; and a dissolved gas amount measuring devicewhich takes a measurement of an amount of the dissolved gas contained inthe liquid sent from the recording head, the dissolved gas amountmeasuring device being disposed on a downstream side of the recordinghead with respect to a flow direction of the liquid, wherein, if theestimate of the amount of the dissolved gas calculated by the dissolvedgas amount calculating device does not exceed the reference value, theliquid restoring device does not carry out restoration processing of theliquid located inside the recording head even in cases where themeasurement of the amount of the dissolved gas taken by the dissolvedgas amount measuring device does exceed the reference value.
 2. Theimage forming apparatus as defined in claim 1, wherein the liquidrestoring device includes a liquid expelling device which expels theliquid located inside the recording head to outside of the recordinghead through discharge holes provided in the recording head.
 3. Theimage forming apparatus as defined in claim 1, further comprising: aliquid supply device which stores the liquid supplied to the recordinghead; and a circulation path provided with the dissolved gas amountmeasuring device, the liquid circulating from the recording head throughthe circulation path to the liquid supply device, wherein: the liquidrestoring device includes a deaerating device which removes at least aportion of the dissolved gas contained in the liquid, the deaeratingdevice being disposed on a downstream side of the liquid supply devicewith respect to the flow direction of the liquid; and if the estimate ofthe amount of the dissolved gas calculated by the dissolved gas amountcalculating device exceeds the reference value, then the liquidrestoring device circulates the liquid located inside the recording headto the liquid supply device through the circulation path, and carriesout deaeration processing of the liquid supplied to the recording headusing the deaerating device in such a manner that the measurement of theamount of the dissolved gas taken by the dissolved gas amount measuringdevice becomes equal to or less than the reference value.
 4. The imageforming apparatus as defined in claim 1, further comprising: a recordinghead temperature adjusting device which adjusts a maintenancetemperature of the recording head; and a recording head temperatureadjustment control device which implements control in such a manner thatthe maintenance temperature of the recording head is lowered using therecording head temperature adjustment device, if the estimate of theamount of the dissolved gas calculated by the dissolved gas amountcalculating device has approached the reference value.
 5. The imageforming apparatus as defined in claim 1, wherein the dissolved gasamount calculating device calculates the estimate of the amount of thedissolved gas contained in the liquid according to a travel time of theliquid moving along a liquid flow path.
 6. An image forming apparatuscomprising: a recording head which discharges droplets of liquid onto arecording medium; a dissolved gas amount calculating device whichcalculates an estimate of an amount of dissolved gas contained in theliquid located inside the recording head, wherein said calculation isbased on properties of the liquid or properties of the image formingapparatus; a liquid restoring device which carries out restorationprocessing of the liquid located inside the recording head, if theestimate of the amount of the dissolved gas calculated by the dissolvedgas amount calculating device exceeds a prescribed reference value; aliquid supply device which stores the liquid supplied to the recordinghead; and a dissolved gas amount measuring device which takes ameasurement of an amount of the dissolved gas contained in the liquidsupplied to the recording head, wherein: the liquid restoring deviceincludes a liquid expelling device which expels the liquid locatedinside the recording head to outside of the recording head throughdischarge holes provided in the recording head, and a deaerating devicewhich removes at least a portion of the dissolved gas contained in theliquid, the deaerating device being disposed on a downstream side of theliquid supply device with respect to the flow direction of the liquid;the dissolved gas amount measuring device is disposed on a downstreamside of the deaerating device with respect to the flow direction of theliquid; the recording head is disposed on a downstream side of thedissolved gas amount measuring device with respect to the flow directionof the liquid; and if the estimate of the amount of the dissolved gascalculated by the dissolved gas amount calculating device exceeds thereference value, then the liquid restoring device expels the liquidlocated inside the recording head to the outside of the recording headby means of the liquid expelling device, takes the measurement of theamount of the dissolved gas contained in the liquid supplied from theliquid supply device to the recording head by the dissolved gas amountmeasuring device, and carries out deaeration processing using thedeaerating device in such a manner that the measurement of the amount ofthe dissolved gas taken by the dissolved gas amount measuring devicebecomes equal to or less than the reference value.
 7. The image formingapparatus as defined in claim 6, further comprising: a recording headtemperature adjusting device which adjusts a maintenance temperature ofthe recording head; and a recording head temperature adjustment controldevice which implements control in such a manner that the maintenancetemperature of the recording head is lowered using the recording headtemperature adjustment device, if the estimate of the amount of thedissolved gas calculated by the dissolved gas amount calculating devicehas approached the reference value.
 8. The image forming apparatus asdefined in claim 6, wherein the dissolved gas amount calculating devicecalculates the estimate of the amount of the dissolved gas contained inthe liquid according to a travel time of the liquid moving along aliquid flow path.